*sigh* So after fixing my vacuum leak and getting the engine back to a normal idle, I now have a problem with the EGR system. So while taking the EGR on and off and on and off (during the vacuum leak project) I guess the threads in the EGR bracket got stripped. There's about 6 inches between the firewall and EGR, and it's only one tripped hole.

Is there a way I can fix the thread with a smaller thread repair tap, or maybe re-tap a larger hole for a larger bolt? I don't want to go with heli-coils because for that I would have to take the intake manifold off, risking another vacuum leak. I'd like to do everything with the engine together.

In the end, I think the best option is to remove the intake manifold, but I really would like to avoid it if possible.